Management system and method for regulating the on-demand electrolytic production of hydrogen and oxygen gas for injection into a combustion engine

ABSTRACT

A system and method of managing an on-demand electrolytic reactor for supplying hydrogen and oxygen gas to an internal combustion engine. The system minimizes reactor&#39;s power consumption and parasitic energy loss generally associated with perpetual reactors. The system comprises a plurality of sensors coupled to the reactor measuring a plurality of reactor parameters, an electronic control unit coupled to the plurality of sensors and the engine, and a reactor control board coupled to the reactor and the electronic control unit. The electronic control unit: monitors the plurality of reactor parameters and the plurality of engine parameters; determines a reactor performance level; determines an engine performance level; determines a change in the engine performance level to forecast a future engine demand level; and determines an ideal reactor performance level corresponding to the engine performance level or the future engine demand level. The reactor control board regulates the reactor by modifying at least one of electrical current supplied to the reactor, electrical voltage supplied to the reactor, and temperature of the reactor.

FIELD

The embodiments described herein relate to a system and method formanaging an on-demand electrolytic reactor for supplying hydrogen andoxygen gas to an internal combustion engine. In particular, theembodiments relate to a management system and method that cansimultaneously reduce emissions and improve the performance of aninternal combustion engine by: determining the reactor performance levelor calculating the amount of gas being generated by the on-demandelectrolytic reactor; monitoring the engine performance level,determining whether the engine performance level would change, i.e.decrease or increase, or remain the same to forecast a future enginedemand level; adjusting the reactor performance level to improve theengine performance ahead of the forecast future engine demand levelmaterializing to minimize parasitic loss associated with reactorsoperating continuously, i.e. reactors that are not capable of adjustingtheir performance level or the level of produced gas according to thereal time engine performance level; and, thereby, improving the engineperformance and reducing emissions.

INTRODUCTION

It has been shown in the art that addition of hydrogen and/or oxygen tothe pre-combustion mixture improves the combustion efficiency ofinternal combustion engines. The improved combustion efficiency mayresult in lowering emissions and/or improving fuel economy. To achievethis result, an electrolytic reactor is responsible to generate hydrogenand oxygen using water. In order to operate, the reactor requires apower source. In case of an add-on reactor that is installed within avehicle, the power source is the vehicle's engine. In absence of aproper management and control system, the reactor operates continuously.The uninterrupted supply of hydrogen and oxygen to the engine may notalways result in reduced emissions or improved fuel economy. Externalconditions, such as level of oxygen in the surrounding air, temperature,altitude, humidity, road surface and its grade, etc., can make theoperation of the reactor unnecessary.

Accordingly, if the reactor functions ceaselessly without control tosupply gas, the engine performance may not be improved. The reactor isdrawing power from the engine to keep generating gas. As a result, thepower produced by the engine is not consumed entirely for the propulsionand vehicle's internal demands, such as recharging the vehicle's batteryor illuminating the road using its lighting system. It is well knownthat addition of a reactor introduces an external demand or load on theengine. If the reactor works continuously without control, the powerdrawn from the engine for the reactor's operation may become a parasiticloss to the engine. As a result, emissions may be reduced withoutimproving the fuel efficiency. There are numerous prior arts addressingaddition of an electrolytic reactor to improve emissions, as discussedbelow. However, none of the references discusses a management andcontrol system that can reduce parasitic engine loss associated withthese reactors to thereby improve the engine performance and fueleconomy and reduce emissions, simultaneously.

De Souza et al. in U.S. Pat. No. 6,332,434 disclose a system and processfor generating hydrogen for use in an internal combustion engine. DeSouza teaches monitoring specific engine parameters and adjusting therate of reaction by regulating the amount of provided electrical energy.In De Souza, the operation of the hydrogen generating system may bemonitored through sensors and corrected when operating outside normalconditions. However, the normal conditions, the control and themonitoring in De Souza are for safety features and not for improving theperformance of the engine. Further, the system in De Souza does notutilize sensors to calculate the amount of the gas being generated. Theamount of the gas produced by the reactor correlates with the powerconsumed by the reactor to generate the gas. As a result, the system inDe Souza cannot monitor the engine's energy loss associated withoperation of the reactor and cannot minimize the loss. In other words,De Souza may be able to improve fuel efficiency but it will neverminimize the impact of the reactor because the system taught by De Souzadoes not minimize the reactor's power consumption.

Fong et al. in US20110303194 disclose systems and methods for improvingcombustion and engine performance through controlled oxyhydrogeninjection. This prior art discloses reading combustion parameters fromthe engine control module and modifying hydrogen production bycontrolling the supplied electrical current. However, Fong et al. do notappear to teach determining the amount of gas generated by the reactor.

Dee et al. in US20110094459 disclose systems and methods for managingthe operation of a modified engine with hydrogen and oxygen injection.Dee teaches dynamically generating hydrogen and oxygen based on engineoperating characteristics by managing the supplied electrical current.Similar to other prior arts cited above, the system as taught by Dee etal does not determine the amount of gas generated by the reactor so asto adjust the reactor operating condition to reduce parasitic engine'senergy loss and improve the engine's efficiency.

As it is evident from the above discussion of prior arts, there iscurrently a need for a managing system that can control on-demandgeneration of hydrogen and oxygen by an electrolytic reactor to reduceemissions and improve fuel economy and engine performancesimultaneously. The inventors' solution is to measure the reactorperformance level by monitoring a plurality of reactor parametersthrough a plurality of sensors, thereby calculating the amount of gasbeing generated, determining the real time engine performance level bymonitoring a plurality of engine parameters, determining a change in theengine performance level to forecast, ahead of time, a future enginedemand level, and adjusting the reactor performance level to produce gasin an amount that can improve the engine performance prior to theforecast future engine demand level taking place. Monitoring the engineperformance in real time can be used to predict the future engine demandlevel; this, in combination with knowing and controlling the reactor'sgas production rate, will provide the means to produce and deliver thegas in real time in an amount that will improve the engine performancewhile the engine is operating either at the determined engineperformance level or at the forecast future engine demand level. Inother words, the reactor does not show a reactionary response to whathas already happened. The reactor is always one step ahead and ready tosupply the engine with the amount of gas required at any instant.

SUMMARY

The embodiments described herein provide in one aspect a system formanaging an on-demand electrolytic reactor for supplying hydrogen andoxygen gas to an internal combustion engine. The system minimizes amountof power drawn from the engine for the reactor to operate and therebythe system minimizes parasitic energy loss generally associated withperpetual reactors. The engine measures and stores a plurality of engineparameters. The system comprises an electronic control unit (“ECU”)connected to a plurality of sensors coupled to the reactor that areconfigured to measure a plurality of reactor parameters and a reactorcontrol board (“RCB”) coupled to the reactor. The electronic controlunit (“ECU”) is configured to monitor the plurality of reactorparameters and the plurality of engine parameters; determine a reactorperformance level based on at least one of the plurality of reactorparameters; determine an engine performance level based on at least oneof the plurality of engine parameters; determine a change in the engineperformance level to forecast a future engine demand level; anddetermine an ideal reactor performance level corresponding to thedetermined engine performance level, or, if a change in the engineperformance level was determined, to the forecast future engine demandlevel. The reactor control board (“RCB”) is configured to regulate thereactor in response to the ideal reactor performance level determined bythe electronic control unit (“ECU”) by modifying at least one ofelectrical current supplied to the reactor, electrical voltage suppliedto the reactor, and temperature of the reactor.

The embodiments described herein provide in another aspect a similarsystem in which the ECU is further configured to recalibrate theplurality of engine parameters stored in the engine based on at leastone of the plurality of reactor parameters.

In another aspect, the ECU of the same system is further configured todetect an occurrence of at least one of the plurality of reactorparameters existing outside a normal operating range and the ECU isfurther configured to regulate the reactor in response to theoccurrence.

In yet another aspect, the plurality of reactor parameters monitored bythe ECU comprises at least one of the following: water tank level,electrolyte level, supplied electrical voltage, supplied electricalcurrent, water tank temperature, reactor temperature, reactor leakage,water pump, gas flow, relative humidity, conductivity of electrolyte,resistance of electrolyte, and concentration of electrolyte.

In the other aspect, the plurality of engine parameters comprises atleast one of: odometer, engine speed, fuel consumption, fuel rate, massair pressure, mass air flow, mileage, distance, fuel rate, exhausttemperature, NO_(x) levels, CO₂ levels, O₂ levels, engine instantaneousfuel economy, engine average fuel economy, engine inlet air mass flowrate, engine demand percent torque, engine percent load at currentspeed, transmission actual gear ratio, transmission current gear, enginecylinder combustion status, engine cylinder knock level, and aftertreatment intake NO_(x) level preliminary FMI, drivetrain, vehicle speedand GPS location.

In one more aspect, the system further comprises a storage modulecoupled to the electronic control unit, the storage module configured tostore the plurality of reactor parameters, the plurality of engineparameters, the reactor performance level, and the engine performancelevel.

In yet one more aspect, the system further comprises a display modulecoupled to the electronic control unit, the display module configured tovisually display a performance indicator based on at least one of: atleast one of the plurality of reactor parameters, at least one of theplurality of engine parameters, the reactor performance level, and theengine performance level.

In another aspect, the system further comprises a communication modulecoupled to the ECU. The communication module is configured to transmit afirst plurality of data to a remote server and receive a secondplurality of data from the remote server. The first plurality of datacomprises the plurality of reactor parameters, the plurality of engineparameters, the reactor performance level, and the engine performancelevel. The second plurality of data comprises the ideal reactorperformance level and instructions to the reactor control board forachieving the ideal reactor performance level. The second plurality ofdata is generated based on at least one of historical trends of thetransmitted first plurality of data and comparison to other firstplurality of data transmitted from other ECUs in communication with theremote server.

In yet another aspect, if the engine is not equipped with an enginecontrol module and the electronic control unit cannot monitor theplurality of engine parameters, the electronic control unit communicateswith the remote server to find similar engine conditions to determinethe ideal reactor performance level.

In yet another aspect, if the engine is equipped with an engine controlmodule, but the electronic control unit is unable to establish aconnection with the engine control module, the electronic control unitcan communicate with the remote server to find similar engine conditionsto determine the ideal reactor performance level.

In yet another aspect, the system determines the ideal reactorperformance level further based on optimizing at least one of engineperformance indicators according to their priorities. The engineperformance indicators comprise the following: fuel efficiency,emissions, engine torque, and engine horsepower.

The embodiments described herein provide in another aspect a method formanaging an on-demand electrolytic reactor for supplying hydrogen andoxygen gas to an internal combustion engine. The method minimizes amountof power drawn from the engine for the reactor to operate. The methodminimizes parasitic energy loss generally associated with perpetualreactors. The reactor and engine are in communication with an electroniccontrol unit. The engine measures and stores a plurality of engineparameters. The method comprises providing a plurality of sensorscoupled to the reactor that are configured to measure a plurality ofreactor parameters, monitoring the plurality of reactor parameters,monitoring the plurality of engine parameters, determining a reactorperformance level based on at least one of the plurality of reactorparameters, determining an engine performance level based at least onone of the plurality of engine parameters, determining a change in theengine performance level to forecast a future engine demand level,determining an ideal reactor performance level corresponding to thedetermined engine performance level, or, if a change in the engineperformance level was determined, to the forecast future engine demandlevel, and regulating the reactor in response to the determined idealreactor performance level by modifying at least one of electricalcurrent supplied to the reactor, electrical voltage supplied to thereactor, and temperature of the reactor.

In yet another aspect, the method further comprises recalibrating theplurality of engine parameters based on at least one of the plurality ofreactor parameters.

In another aspect, the method further comprises detecting an occurrenceof at least one of the plurality of reactor parameters existing outsidea normal operating range and regulating the reactor in response to theoccurrence.

In one more aspect, the plurality of reactor parameters comprises atleast one of water tank level, electrolyte level, supplied electricalvoltage, supplied electrical current, water tank temperature, reactortemperature, reactor leakage, water pump, gas flow, relative humidity,conductivity of electrolyte, resistivity of electrolyte, andconcentration of electrolyte.

In another aspect, the plurality of engine parameters comprises at leastone of odometer, engine speed, fuel consumption, fuel rate, mass airpressure, mass air flow, mileage, distance, fuel rate, exhausttemperature, NO_(x) levels, CO₂ levels, O₂ levels, engine instantaneousfuel economy, engine average fuel economy, engine inlet air mass flowrate, engine demand percent torque, engine percent load at currentspeed, transmission actual gear ratio, transmission current gear, enginecylinder combustion status, engine cylinder knock level, and aftertreatment intake NO_(x) level preliminary FMI, drivetrain, vehiclespeed, and GPS location.

In yet another aspect, the method further comprises storing theplurality of reactor parameters, the plurality of engine parameters, thereactor performance level, and the engine performance level.

In one more aspect, the method further comprises visually displaying atleast a performance indicator based on at least one of at least one ofthe plurality of reactor parameters, at least one of the plurality ofengine parameters, the reactor performance level, and the engineperformance level.

In another aspect, the method further comprises transmitting a firstplurality of data to a remote server and receiving a second plurality ofdata from the remote server. The first plurality of data comprises theplurality of reactor parameters, the plurality of engine parameters, thereactor performance level, and the engine performance level. The secondplurality of data comprises the ideal reactor performance level andinstructions to the electronic control unit for achieving the idealreactor performance level. The second plurality of data is generatedbased on at least one of historical trends of the transmitted firstplurality of data and comparison to other first plurality of datatransmitted from other engines to the remote server.

In yet another aspect, the ideal reactor performance level is determinedfurther based on optimizing at least one of engine performanceindicators, wherein the engine performance indicators comprise fuelefficiency, emissions, engine torque, and engine horsepower. The methodfurther comprises prioritizing each of the engine performanceindicators, determining the ideal reactor performance level required tooptimize each of the engine performance indicators ranked from highestto lowest and optimizing the reactor performance to achieve an improvedengine performance based on aggregate of the determined idea reactorperformance levels.

Further aspects and advantages of the embodiments described herein willappear from the following description taken together with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the embodiments described herein and toshow more clearly how they may be carried into effect, reference willnow be made, by way of example only, to the accompanying drawings whichshow at least one exemplary embodiment, and in which:

FIG. 1 is a block diagram of interactions between various components,such as engine, electronic control module (“ECM”), electronic controlunit (“ECU”), reactor and reactor control board (“RCB”) of the system ofmanaging the electrolytic reaction for generating hydrogen gas to beinjected to an internal combustion engine;

FIG. 2 is a block diagram of the system which further comprises astorage module coupled to the ECU to store reactor parameters, engineparameters, reactor performance level, and engine performance level;

FIG. 3 is a block diagram of the system which further comprises adisplay module coupled to the ECU to visually display a performanceindicator;

FIG. 4 is a block diagram of the system which further comprises a remoteserver in communication with the ECU to receive data from the ECU andsend data to the ECU;

FIG. 5 is a block diagram of the system which further comprises astorage module, display module, and remote server, all in communicationwith the ECU;

FIG. 6 is a flowchart of the steps performed by the system in managingthe electrolytic reaction for generating hydrogen gas to be injected toan internal combustion engine;

FIG. 7 is a flowchart of the steps performed by the system to detect afault condition within the reactor and to rectify such condition;

FIG. 8 is a flowchart of the steps performed by the system when it iscoupled to a storage module;

FIG. 9 is a flowchart of the steps performed by the system when it iscoupled to a display module; and

FIG. 10 is a flowchart of the steps performed by the system when it isin communication with a remote server.

The skilled person in the art will understand that the drawings,described below, are for illustration purposes only. The drawings arenot intended to limit the scope of the applicants' teachings in anyway.Also, it will be appreciated that for simplicity and clarity ofillustration, elements shown in the figures have not necessarily beendrawn to scale. For example, the dimensions of some of the elements maybe exaggerated relative to other elements for clarity. Further, whereconsidered appropriate, reference numerals may be repeated among thefigures to indicate corresponding or analogous elements.

DESCRIPTION OF VARIOUS EMBODIMENTS

It will be appreciated that numerous specific details are set forth inorder to provide a thorough understanding of the exemplary embodimentsdescribed herein. However, it will be understood by those of ordinaryskill in the art that the embodiments described herein may be practicedwithout these specific details. In other instances, well-known methods,procedures and components have not been described in detail so as not toobscure the embodiments described herein. Furthermore, this descriptionis not to be considered as limiting the scope of the embodimentsdescribed herein in any way, but rather as merely describing theimplementation of the various embodiments described herein.

One or more systems described herein may be implemented in computerprograms executing on programmable computers, each comprising at leastone processor, a data storage system (including volatile andnon-volatile memory and/or storage elements), at least one input device,and at least one output device. For example, and without limitation, theprogrammable computer may be a programmable logic unit, a mainframecomputer, server, and personal computer, cloud based program or system,laptop, personal data assistance, cellular telephone, smartphone, ortablet device.

Each program is preferably implemented in a high level procedural orobject oriented programming and/or scripting language to communicatewith a computer system. However, the programs can be implemented inassembly or machine language, if desired. In any case, the language maybe a compiled or interpreted language. Each such computer program ispreferably stored on a storage media or a device readable by a generalor special purpose programmable computer for configuring and operatingthe computer when the storage media or device is read by the computer toperform the procedures described herein.

Referring now to FIG. 1, FIG. 1 is a block diagram illustrating anexemplary embodiment of system 100 that manages electrolytic reaction ofan on-demand reactor 102 for generating hydrogen and oxygen gas to beinjected into an internal combustion engine 104 so as to reduceemissions, improve fuel economy and improve engine performance. System100 comprises a number of functional elements including a reactor 102,an engine 104, an engine control module (“ECM”) 106, an electroniccontrol unit (“ECU”) 108, a plurality of sensors 110 coupled to thereactor 102, and a reactor control board (“RCB”) 112. The ECU 108 is thecommander or decision-making unit of the system 100. The ECU 108together with the RCB 112 form the control set (not shown) of the system100. Upon starting the engine 104, the ECU 108 powers on and receivespower from the engine's ignition signal. This signal is provided whenthe ignition is turned on.

After the power-on stage, the system 100 performs a self-check. Theself-check is a built-in function of the ECU 108's micro-controller (notshown) that performs initialization of the ECU 108's input and outputpins as well as initialization of the RCB 112 and the plurality ofsensors 110. The system 100 then moves on to perform self-monitoring andoperation steps.

In the first step of self-monitoring steps, the ECU 108 performs a leakcheck on the reactor 102. A subroutine is used to detect a leak andprevent a false positive. If a leak is detected, the subroutine returnsa value indicating so, and generates a fault code.

Next, the ECU 108 performs a temperature check on the reactor 102. Asubroutine is used to monitor the reactor 102's temperature and controlthe reactor 102's heater (not shown) to an optimal temperature for thereactor 102.

Next, the ECU 108 performs a temperature check on the water reservoir(not shown). A subroutine is used to monitor the water reservoirtemperature and control the water reservoir heater to an optimaltemperature for the water.

Next, the ECU 108 performs the reactor 102 voltage check. A subroutineis used to check that the voltage is in the optimal range. The RCB 112has built-in circuitry to measure and control the voltage. The ECU 108records the value and compares it with the optimal range. If the ECU 108determines that the voltage is not within, and cannot be adjusted to,the optimal range, it returns a fault code.

Next, the ECU 108 performs a level check of the water reservoir. Asubroutine is used to measure the water reservoir level (not shown)connected to the reactor 102. The subroutine has 2 levels. If the ECU108 receives an “add water” signal for the first level associated withthe “operator fill” level, it returns a warning to the operator to topup the tank (not shown). If the ECU 108 receives a signal for the secondlevel associated with the pump (not shown), the ECU 108 will not allowthe pump to turn on, preventing damage to the pump and system 100. TheECU 108 will eventually shut the reactor 102 off to prevent furtherdamage in the event that no water is added to the reservoir.

Next, the ECU performs a resistance check on the reactor 102. Asubroutine is used to measure the resistance of the electrolyte. Asensor among the plurality of sensors 110, in contact with theelectrolyte, is used to measure the resistance. The value can be used todetermine the concentration and conductivity of the electrolyte. Thisinformation may be useful in the high precision gas flow calculation,discussed below.

After the self-monitoring steps, described above, the system 100 moveson to perform operation steps. The first step is to power up the reactor102.

The ECU 108 will determine if the reactor 102 can be powered up based onthe status of the self-monitored checks, above. If the ECU 108 powers onthe reactor 102 and no water is added to the reactor 102, the ECU 108will shut the reactor 102 down when it reaches a low electrolyte state.When the ECU 108 determines that the reactor 102 is ready, it then turnson the reactor 102. To do so, the ECU 108 sends a signal to the RCB 112allowing the current to flow through the reactor 102.

Then, the ECU 108 performs a reactor 102 amperage check; this is part ofthe self-monitoring subroutine. The subroutine is used to measure theamperage that the reactor 102 is drawing. The RCB 112 has built incircuitry to measure and control the amperage to the reactor 102. Themeasured amperage is an indicator that the reactor 102 is operating. TheECU 108 compares the measured amperage to the optimal amperage andadjusts it accordingly. The RCB 112 can control the voltage and currentto adjust the reactor 102's power consumption to optimal performance.The ECU 108 controls the RCB 112 and the reactor 102's temperature forachieving optimal performance.

Similar to other steps, subroutines are programmed in the ECU 108'smicrocontroller to gather and record plurality of sensors 110 data. TheECU 108 uses the gathered data to measure a plurality of reactorparameters, thereby to calculate the reactor performance level or gasproduction rate while the reactor 102 is running. To achieve the goal ofimproving the engine 104's performance, the ECU 108 calculates theperformance of the engine 104 (i.e. determines the engine performanceindicators and priority, as described in more detail below) bymonitoring a plurality of engine parameters to determine how to adjustthe reactor performance level (or gas production rate) so as to improvethe engine 104's performance. The steps associated with this stage ofthe managing system 100 are illustrated in FIG. 6 and discussed in moredetail below.

Referring now to FIGS. 1 and 6, FIG. 6 is a flowchart that illustratesbasic steps 600 taken by the system 100 to improve the engine 104'sperformance. The process begins at step 602. At step 604, the ECU 108monitors the plurality of reactor parameters by means of monitoring theplurality of sensors 110, as described below. At step 606, the ECU 108determines the reactor performance level based on the data gathered fromthe plurality of sensors 110 in step 604; this is the initial reactor102 state. At step 608, the ECU 108 monitors the plurality of engineparameters either directly from the engine 104, in the event the engine104 is not equipped with an ECM 106, or from the data stored within theECM 106. At step 610, the ECU 108 determines the engine performancelevel based on the data gathered in step 608; this is the initial engine104 state, or its baseline performance. At step 611, the ECU 108determines changes that may occur in the determined engine performancelevel by continuing to monitor the engine performance level so that itcan forecast a future engine demand level. Then, at step 612, the ECU108 determines a gas production rate or reactor performance level thatcan improve the engine performance while the engine is operating at thedetermined engine performance level or, if changes in the performancewere detected in step 611, while the engine is operating at the forecastfuture engine demand level. The reactor performance level or gasproduction rate at step 612 is called “ideal reactor performance level”as when the reactor 102 operates at this level it can supply an amountof gas corresponding to the determined engine performance level at step610, or, if changes detected at step 611, corresponding to the forecastfuture engine demand level, to the engine 104 at exactly the moment theengine 104 is about to operate at the respective performance or demandlevel. This is the algorithm through which the system 100 improves theengine 104's performance in real time. In other words, the system 100 isalways one step ahead of the engine; the system 100 does not show areactionary response to what already has taken place. Finally, at step614, the ECU 108 through the RCB 112 modifies at least one of, but notlimited to, the electrical current supplied to the reactor 102, theelectrical voltage supplied to the reactor 102, and the temperature ofthe reactor 102 to achieve the ideal reactor performance level.

The steps described above are repeated while the engine 104 is running.In other words, the performance of the reactor 102 is being optimizedconstantly, by constantly determining a new ideal reactor performancelevel corresponding to upcoming engine 104's demand, to continuouslyimprove the engine 104's performance while the engine 104 is running. Inaddition to determining the engine performance level at any moment, theECU 108 continuously monitors the plurality of engine parameters todetermine any change in the engine performance level and to forecast afuture engine demand level. In other words, the ECU 108 can predict thedemand that is going to be placed on the engine in future. The ECU 108then optimizes the reactor 102's performance by commanding it to operateat the ideal reactor performance level corresponding to the determinedengine performance level, if the engine is still operating at thatlevel, or the forecast future engine demand level, if the engine isabout to operate at this level, to improve the engine 104's performanceat real time, i.e. not showing a reactionary response.

The initially measured engine performance level is established as abaseline, as discussed above. The ECU 108 then calculates the reactorperformance level or gas production rate, as discussed below, foroptimizing the reactor 102's performance and data logging the reactorperformance level corresponding to the baseline engine performancelevel. Thereafter, the ECU 108 monitors the plurality of engineparameters to detect changes in the engine performance level, i.e. asign of change in the engine 104's demand. If the engine 104's demandand the engine performance level change, the ECU 108 controls thereactor 102 via the RCB 112 to adjust the reactor performance level orgas production rate to improve the engine 104's performance. The ECU 108further forecasts if the changes in the engine performance level or theengine 104's demand are going to continue based on the engine 104'sparameters such as throttle positions, etc. This is the forecasting thattakes place at step 611.

In addition to reading the plurality of engine parameters to determine achange in the engine 104's demand and the engine performance level, theECU 108 also uses the telemetry parameters such as GPS data, terraincondition, etc. to better forecast the future engine demand level andthe required reactor performance level or gas production rate.

This method allows the ECU 108, in advance, to estimate the requiredreactor performance level in preparation for forecast changes in theengine 104's demand, i.e. the forecast future engine demand level. Inother words, knowing the reactor performance level, the amount of gasbeing generated, the engine performance level, and the forecast changesprovide the necessary information to the ECU 108 to estimate and controlthe reactor performance level, or gas production rate, as a means forcontrolling the actual amount of gas being delivered to the engine 104.Using this information, in combination with determining the engineperformance level and forecasting the future engine demand level,results in the ability to adjust the reactor performance level or amountof gas production in a way that optimizes the reactor 102's performanceahead of the engine 104's demand. That is, the gas enters the combustionchamber as the change in the engine performance level occurs, i.e. whenthe engine 104 operates at the forecast future engine demand level, andnot afterwards in response to changes.

This also means that the reactor 102 settings are automatically adjustedso that only the necessary power is used to create the required gas. Forinstance, if only 1 liter of gas is required, the ECU 108 controls thereactor 102 via the RCB 112 to use the minimum power required to producethat amount of gas. As described below, this operation method of system100 results in improving the engine 104's performance, based on thepriority of the performance indicators, while minimizing the reactor102's power consumption and optimizing the performance of the reactor102 while simultaneously improving the fuel efficiency and reducingemissions.

The following paragraphs discuss the aforementioned steps in moredetail.

Referring again to FIGS. 1 and 6, to calculate the reactor performancelevel or gas production rate at step 606, the ECU 108 reads values onamperage, voltage, electrolyte conductivity and concentration, andtemperature value, i.e. the plurality of reactor and engine parameters,from the plurality of sensors 110 at step 604. Each ECU 108 has anin-house calibration chart programmed into its microcontroller that mapsthe hydrogen and oxygen production and parameter values. The datagathered from the plurality of sensors 110 at step 604 is used to finetune the calculation performed at step 606 by comparing the measuredvalues against the baseline values or previous performance levels. Thisalso has the added benefit that the system 100 does not need to beequipped with expensive gas flow meters to determine the gas beingdelivered to the engine.

To further determine a more accurate reactor performance level or gasproduction rate, the ECU 108, in addition to using the electrical powerconsumed by the reactor 102 (Power=Voltage×Electrical Current), canfactor in for the variance in temperature and variance in concentrationof electrolyte. Initially, the reactor performance level is determinedat a calibration temperature. The reactor 102 will inherently heat up onits own and without controlling the power there is a possibility thatthe reactor 102 will overheat. When the power is limited, the reactor102's temperature should stabilize. For calibration, the power islimited and the reactor 102 is allowed to stabilize. The gas productionand temperature that are measured initially define the reactor 102'sbaseline for performance, as referred to above. This means the ECU 108needs to take into account an adjustment for temperature in furthercalculations of the reactor performance level.

Consequently, the ECU 108 adjusts the reactor performance level or gasproduction rate, calculated at step 606, by means of taking into accountamperage, voltage, temperature, and/or electrolyte concentration.Thereafter, the ECU 108 returns this adjusted value as the reactorperformance level or gas production rate.

The calculations at step 606 may be based on one of, but not limited to,the plurality of sensors 110 monitoring the plurality of reactorparameters, depending on the process or calculation.

Before moving on to the next step of determining the engine performancelevel, step 610, the importance of monitoring the electrolyteconcentration and conductivity should be highlighted. As discussedabove, the concentration is monitored at step 604 as part of determiningthe reactor performance level or gas production rate at step 606; theconcentration changes during operation and will have a small effect onthe gas production. In addition, the monitoring of electrolyteconcentration is used to check that the electrolyte is not lost or notcrystalized and to confirm that water has been added to the reactor 102when required. The concentration will vary as the water is converted togas. If the concentration is out of a predetermined range and the ECU108 cannot correct the issue by demanding the pump to add water, the ECU108 indicates a fault and prevents the system 100 from furtheroperation. The electrolyte is a catalyst and should not get used up.Crystallization and electrolyte loss will lead to a unit failure.

As discussed, the ECU 108 also uses monitoring of the electrolyteconcentration to determine the reactor performance level (or the amountof gas being generated) at step 606. Gas production calculations basedon the power consumption (derived from those plurality of sensors 110measuring voltage and amperage, through the following formulaPower=Voltage×Electrical Current) are more accurate when adjusted byintroducing the concentration and conductivity of the electrolyte intothe equation. As the water is decomposed into gas, the concentrationlevel will change. This change affects the gas production to a certaindegree.

Moving to the next step of determining the engine performance level,step 610, the ECU 108 interacts with the engine 104, or the ECM 106,using built-in circuitry to monitor the plurality of engine parametersat step 608, discussed below. The plurality of engine parameters ismonitored in order to observe the engine 104's operation and performancechanges. This allows the ECU 108 to determine the ideal reactorperformance level required for improving the engine performance.Changes, determined in step 611, in each of the monitored plurality ofengine parameters at step 608 indicate whether the engine 104 needs tosupply more power or less power, i.e. whether the engine 104's demand orthe engine performance level is increasing or decreasing. Determiningchanges can be used to forecast a future engine demand level. It is alsoupon determining a change in the engine 104's demand or the engineperformance level that the ECU 108, at step 614, controls the RCB 112 toadjust the reactor performance level or gas production rate to improvethe engine 104's performance when the engine 104 is in fact operating atthe forecast future engine demand level.

The ECU 108 monitors either through the ECM 106, if available, ordirectly, at least one of, but not limited to, the followingnon-exhaustive list of the plurality of engine parameters at step 608 todetermine the engine performance at step 610 and to determine a changesin the engine performance level to forecast a future engine demand levelat step 611: odometer, vehicle speed, engine speed, fuel consumption,fuel rate, mass air pressure, mass air flow, mileage, distance, fuelrate, exhaust temperature, NO_(x) sensors, CO₂ sensors, O₂ sensors,engine instantaneous fuel economy, engine average fuel economy, engineinlet air mass flow rate, engine demand—percent torque, engine percentload at current speed, transmission actual gear ratio, transmissioncurrent gear, engine cylinder combustion status (all cylinders), enginecylinder knock level (all cylinders), after treatment intake NO_(x)sensor preliminary FMI (all banks), etc.

As discussed, the ECU 108 controls the amount of gas delivered to theengine 104 intake by determining the engine performance level in orderto improve the combustion process. The ECU 108 is also able torecalibrate some of the plurality of engine parameters, not changing theprogramming, so that the ECM 106 can adapt to addition of the gasses tothe combustion chamber. Moreover, as discussed below, it should be notedthat the ECU 108 records the reactor performance level and engineperformance level for future analysis and improvement of the system 100.

Now that the ECU 108 has determined the engine performance level at step610, and the forecast future engine demand level at step 611, it needsto control the RCB 112 to adjust the reactor performance level, or gasproduction rate, to improve the engine 104's performance while theengine 104 is operating at the determined engine performance level or,due to changes determined at step 611, operating at the forecast futureengine demand level. The ECU 108 uses the gathered data from steps604-611 to determine an ideal reactor performance level at step 612 andsend the determined ideal reactor performance level to the RCB 112 atstep 614. In addition to the data gathered from the engine 104 and thereactor 102, the ECU 108 also uses telemetry parameters such as GPSdata, terrain condition, etc. in determining and forecasting the currentand future engine 104's demands, corresponding engine performancelevels, and the corresponding ideal reactor performance level.

The reactor 102 now needs to operate according to the determined idealreactor performance level at step 612. The RCB 112 is designed tocontrols the reactor in order to control and adjust the amount of gasbeing delivered to the engine. The RCB 112 has a custom builtmicrocontroller controlling, but not limited to, a pulse width modulator(PWM) and a current sensor. It may also have a voltage and/or afrequency modulator along with corresponding sensors. At step 614, theRCB 112 can measure and control the reactor 102's performance throughintegrated circuitry based on instructions received from the ECU 108.The RCB 112 also has a humidity-temperature sensor and a communicationlink, discussed below.

At step 604, the RCB 112 monitors the amperage as part of theself-monitoring subroutine. The RCB 112 measures the power that thereactor 102 is drawing and adjusts the amperage using the PWM to meetthe power requirements instructed by the ECU 108. The RCB 112 raises orlowers the amperage to control the reactor performance level or gasproduction rate, as determined by the ECU 108, provided the power iswithin the limits. The RCB 112 also monitors the reactor 102temperature, as part of the self-monitoring subroutine, through anintegrated temperature sensor. The RCB 112 and the ECU 108 interacts tocontrol the heater and fan to adjust the reactor temperature.

An increased temperature aids in the electrolytic process of water to acertain degree. As the temperature rises, the decomposition potential,the energy required for splitting water into gas, is lowered. The RCB112 uses this information to raise the temperature if higher reactorperformance level or more gas production rate is needed withoutincreasing the amperage. By increasing the temperature rather than theamperage, the power drawn from the engine 104 can be reduced and therebythe engine 104's performance or efficiency is increased, as discussedbelow. Further, monitoring the temperature prevents the reactor 102 fromoverheating.

In summary, the ECU 108, in steps 602-614, interacts with the engine104, or ECM 106, the plurality of sensors 110 and RCB 112 to determinethe reactor performance level and engine performance level. The ECU 108controls the RBC 112 to control the pulse width modulation circuit (notshown) to control the amount of current available to the reactor 102 andthereby to adjust the reactor performance level or gas production rateto improve the engine 104's performance while the engine 104 isoperating at the determined engine performance level or forecast futureengine demand level. This adjusted reactor performance level is referredto as the ideal reactor performance level.

It should be noted that, as discussed, the ECU 108 is the commander ormajor decision-making unit of the system 100. In other words, the RCB112 is a slave to the ECU 108. However, the RCB 112 is equipped with acommunication link as well. Through the communication link, the RCB 112can gather other auxiliary information to provide further control in theevent the ECU 108 is not part of the system 100.

Finally, when the reactor 102 is not required to operate anymore, theECU 108 performs a shut down cycle. Before turning the unit off, the ECU108 determines the reactor 102 electrolyte level and reservoir waterlevel. If the water level is low, the ECU 108 indicates to the operatorto fill the water reservoir. The ECU 108 will fill the reactor providedthere is sufficient water in the reservoir. The cycle has a timer toallow the reactor to settle; the electrolyte level will change slightlyafter operation. The ECU 108 has a shut down cycle that uses an internalbattery to power some functions to prepare the system 100 for immediateoperation next time it is turned on. The shut down cycle is initiatedwhen there is no longer an ignition signal powering the ECU 108.

As discussed, the reactor performance level or gas production rate isdirectly related to the power that the reactor 102 draws from the engine104 to generate gas. Knowing the reactor performance level, the idealreactor performance level, and the engine performance level, or theforecast future engine demand level, will allow the system 100 tominimize the parasitic power loss from the engine 104. The reactor 102uses a portion of the power produced by the engine 104 to run. When theamount of gas generated by the reactor 102 is more than the demand tomeet the real time engine performance level, the reactor 102 is usingmore power from the engine 104 than is necessary. This adds to theparasitic energy loss. Since the system 100 can adjust the reactorperformance level according to the real time engine performance level,this parasitic loss can be minimized. By controlling and optimizing thereactor 102's performance, when the engine performance level does notdemand a higher gas production rate from the reactor 102, the system 100places less load on the engine 104. In other words, the system 100achieves one of the objectives of this invention, namely to reduceemissions and improve fuel efficiency simultaneously while minimizingthe power consumption of the reactor 102.

Referring now to FIGS. 1 and 7, FIG. 7 is a flowchart that illustratesbasic steps 700 taken by the system 100 to detect faults within thesystem 100. The process begins at step 702. At step 704, the ECU 108gathers data on the plurality of reactor parameters by means ofmonitoring the plurality of sensors 110. At step 706, the ECU 108 checksfor an occurrence of at least one of, but not limited to, the pluralityof reactor parameters existing outside a normal operating range based onthe data gathered from the plurality of sensors 110 in step 704. At step708, if the ECU 108 determines that at least one of the plurality ofreactor parameters is outside a normal operating range, it moves to step710. Otherwise, it moves back to step 704 to monitor the plurality ofreactor parameters again. At step 710, the ECU 108 orders the RCB 112 toregulate the reactor 102 in response to the occurrence detected at step708.

The ECU 108 has the intelligence to use the information it gathers atstep 704 to determine whether the unit is inside the normal operatingconditions or not. The ECU 108 has the ability to change operationalparameters to correct fault conditions, when needed, at step 710. TheECU 108 has the logic to determine if the changes to correct thefault(s) are having an effect or not. The ECU 108 fault detection isdesigned to protect the engine 104 from being damaged as well as thesystem 100 itself. The fault detection is designed in a fail-safemanner. The ECU 108 programming also has built-in corrective actions tobe taken to keep the system 100 operational for as long as possible,without causing damage, if a fault occurs. At step 710, the ECU 108shuts the reactor 102 off if the corrective actions are not having thedesired effect to prevent damage to the engine 104 or reactor 102.

The plurality of reactor parameters that are monitored by the ECU 108 atstep 704 comprises the following non-exhaustive list: water tank level,electrolyte level, supplied electrical voltage, supplied electricalcurrent, water tank temperature, reactor temperature, reactor leakage,water pump, gas flow, relative humidity, conductivity of electrolyte,resistance of electrolyte, concentration of electrolyte, etc.

At step 704, the ECU 108 monitors the water tank level and providesindication when water needs to be added to the reservoir of the system100. This also serves to protect the water pump from running when thereis not enough water in the tank. The ECU 108 eventually shuts thereactor 102 off at step 710 to prevent further damage in the event thatno water is added to the reservoir.

At step 704, the ECU 108 monitors the reactor 102 electrolyte level andwill add water to the reactor 102 when needed. The ECU 108 eventuallyshuts the system 100 off at step 710 in the event that no water is addedto the reactor 102.

At step 704, the ECU 108 monitors the electrolyte concentration. Theconcentration is also monitored as part of determining the reactorperformance level or the amount of gas being generated, as discussedabove. This monitoring, at step 704, is also used to check that theelectrolyte is not crystallizing and to confirm that water has beenadded to the reactor 102 when required. The concentration will vary asthe water is added to the reactor 102 or converted to gas. If theconcentration is out of a predetermined range and the ECU 108 cannotcorrect the issue, the ECU 108 indicates a fault at step 710.

At step 704, the ECU 108 measures the voltage to determine, at step 706,how much voltage is available before the reactor 102 is powered up. Italso determines the power the reactor 102 is drawing and ensures thereactor 102 does not drain the vehicle battery in the event that theengine 104's alternator fails or if the ignition is left on without theengine 104 running. If the voltage is outside the working range, the ECU108 shuts the reactor 102 off and indicates a fault at step 710.

At step 704, the ECU 108 measures the current to determine, at step 706,the power the reactor 102 is drawing and to ensure that the reactor 102is operating at the specified amperage for the desired reactorperformance level or gas production rate. As discussed above, this isone of the ways that the ECU 108 controls the reactor performance levelor the gas production rate. If the amperage is outside the workingrange, the ECU 108 shuts the reactor 102 off and indicates a fault atstep 710.

At step 704, the ECU 108 measures the water tank temperature to ensurethat the water is liquid and not solid. If, at step 706, the temperatureis determined to be below 8° C., the ECU 108 turns on the tank heater tobring the water to operational temperature at step 710.

At step 704, the ECU 108 measures the reactor 102 temperature to monitorits performance and ensure the reactor 102 does not over-heat. At step706, the ECU 108 determines if the temperature is optimal. The ECU 108turns on the reactor 102 heater to bring it up to optimal temperature atstep 710. It also shuts the reactor 102 down in the event that thereactor 102 starts to overheat.

At step 704, the ECU 108 monitors the reactor 102 for leaks. The ECU 108at step 706 determines if the leak is a false positive or an actualleak. If the leak is determined to be true the ECU 108 shuts down thereactor 102 and indicates a fault at step 710.

Referring now to FIG. 2, FIG. 2 is a block diagram illustrating anotherexemplary embodiment of the system 100. System 200 comprises a number offunctional elements including a reactor 202, an engine 204, an enginecontrol module (“ECM”) 206, an electronic control unit (“ECU”) 208, aplurality of sensors 210 coupled to the reactor 202, a reactor controlboard (“RCB”) 212, and a storage module 214 coupled to the ECU 208.Other than the storage module 214, other components are similar to thosedescribed above and illustrated in FIG. 1. As a result, these componentsare referred to using reference numerals corresponding to FIG. 1.

The storage module 214 is configured to store the plurality of reactorparameters, the plurality of engine parameters, the reactor performancelevel and the engine performance level. The ECU 108 uses the storagemodule 214 to log and record data for further analysis to createperformance improvements. The ECU 108 also logs the data for futurereporting.

Referring now to FIGS. 1, 2 and 8, FIG. 8 is a flowchart thatillustrates basic steps 800 taken by the system 100 or 200 to store theplurality of reactor parameters, the plurality of engine parameters, thereactor performance level, and the engine performance level. The processbegins at step 802. At step 804, the ECU 108 gathers data on theplurality of reactor parameters by means of monitoring the plurality ofsensors 110 or 210. At step 806, the ECU 108 determines the reactorperformance level based on the data gathered from the plurality ofsensors 110 in step 804. At step 808, the ECU 108 gathers data on theplurality of engine parameters. At step 810, the ECU 108 determines theengine performance level based on the data gathered in step 808.Finally, at step 812, the ECU 108 stores the monitored plurality ofreactor parameters and plurality of engine parameters along with thedetermined reactor performance level and engine performance level in thestorage module 214.

Referring now to FIG. 3, FIG. 3 is a block diagram illustrating anotherexemplary embodiment of system 100. System 300 comprises a number offunctional elements including a reactor 302, an engine 304, an enginecontrol module (“ECM”) 306, an electronic control unit (“ECU”) 308, aplurality of sensors 310 coupled to the reactor 302, a reactor controlboard (“RCB”) 312, and a display module 314 coupled to the ECU 308.Other than the display module 314, other components are similar to thosedescribed above and illustrated in FIG. 1. As a result, these componentsare referred to using reference numerals corresponding to FIG. 1.

Referring to FIGS. 1 and 3, the display module is configured to visuallydisplay a performance indicator based on the plurality of reactorparameters, the plurality of engine parameters, the reactor performancelevel and the engine performance level. The display module 314 is themain focal point for the operator to interface with system 100. Theinformation and communication are controlled by the ECU 108. The displaymodule 314 updates the driver on the performance of the reactor 102 andthe engine 104. It also allows the operator to control and setupspecific parameters for the reactor 102. Different customers may havedifferent applications for system 100 and the display module 314provides the interaction for customizing the available parameters tomeet their needs. Further, the ECU 108 can communicate with the displaymodule 314 to display the necessary information to a user to keep thesystem 100 in optimal work order or to inform the user to performservice on the system 100.

Referring now to FIGS. 1, 3 and 9, FIG. 9 is a flowchart thatillustrates basic steps 900 taken by the system 100 or 300 to visuallydisplay the plurality of reactor parameters, the plurality of engineparameters, the reactor performance level, and the engine performancelevel. The process begins at step 902. At step 904, the ECU 108 gathersdata on the plurality of reactor parameters by means of monitoring theplurality of sensors 110 or 310. At step 906, the ECU 108 determines thereactor performance level based on the data gathered from the pluralityof sensors 110 in step 904. At step 908, the ECU 108 gathers data on theplurality of engine parameters. At step 910, the ECU 108 determines theengine performance level based on the data gathered in step 908.Finally, at step 912, the ECU 108 can visually display one or many ofthe monitored plurality of reactor parameters and the plurality ofengine parameters along with determined reactor performance level andengine performance level via the display module 314.

Referring now to FIG. 4, FIG. 4 is a block diagram illustrating anotherexemplary embodiment of system 100. System 400 comprises a number offunctional elements including a reactor 402, an engine 404, an enginecontrol module (“ECM”) 406, an electronic control unit (“ECU”) 408, aplurality of sensors 410 coupled to the reactor 402, a reactor controlboard (“RCB”) 412, and a remote server 414 in communication with the ECU408. Other than the remote server 414, other components are similar tothose described above and illustrated in FIG. 1. As a result, thesecomponents are referred to using reference numerals corresponding toFIG. 1.

Referring to FIGS. 1 and 4, the ECU 108 is able to transmit performancelogs and other specified data to a portal to be compiled and put into areport. The data that is logged and used by the ECU 108 during theinitial trip to improve the performance of the engine 104 and optimizethe performance of the reactor 102 is uploaded to the remote server 414at the end of the trip. The received data is analyzed to determine ifany improvements can be made to the logic of the system 100 to improvethe engine 104's performance. A human operator or a computer program isresponsible for conducting said analysis. The improvements may beapplied to other ECUs, associated with other engines, in communicationwith the remote server 414 that have similar conditions. The existenceof the remote server 414 is crucial in report generating.

Moreover, the ECU 108 is not limited to transmitting data only at theend of each trip. The ECU 108 can set a data transmission intervalduring each trip and send data to the remote server 414 accordingly. Thereceived data is stored in the remote server 414 and a trend ofhistorical data is created for every ECU 108 in communication with theremote server 414. Upon receiving the data, an analysis is conducted.The data is compared to historical trends and data received from otherECUs that are in communication with the remote server 414. If the humanoperator or the computer program determines that an improvement to theperformance of the engine 104 and the reactor 102 is available, based onthe aforementioned analysis, the remote server 414 sends instructions tothe ECU 108 in order to improve the engine 104 and the reactor 102performance. If the remote server 414 determines that the performanceimprovement is also applicable to other ECUs associated with otherengines in communication with the remote server 414, it sends similarinstructions to those ECUs as well.

In order to transmit and receive data to and from the remote server 414,the ECU 108 needs to establish a connection with the remote server 414.The ECU 108 is able to connect through multiple methods to transfer thecorrect data and information. The ECU 108 has built-in radios, such asGPRS, WIFI, and/or Bluetooth, for communication with external devicesfor the interaction and transfer of data. The ECU 108 has USB ports toofor wired communications. Further, after each instance of datatransmission, the ECU 108 receives and sends a confirmation that datahas been transmitted successfully.

Referring now to FIGS. 1, 4 and 10, FIG. 10 is a flowchart thatillustrates basic steps 1000 taken by managing system 100 or 400 tocommunicate with the remote server 414 and transmit the plurality ofreactor parameters, the plurality of engine parameters, the reactorperformance level, and the engine performance level. The process beginsat step 1002. At step 1004, the ECU 108 gathers data on the plurality ofreactor parameters by means of monitoring the plurality of sensors 110or 410. At step 1006, the ECU 108 determines the reactor performancelevel based on the data gathered from the plurality of sensors 110 instep 1004. At step 1008, the ECU 108 monitors the plurality of engineparameters. At step 1010, the ECU 108 determines the engine performancelevel based on the data gathered in step 1008. At step 1012, the ECU 108transmits the monitored plurality of reactor parameters and plurality ofengine parameters along with determined reactor performance level andengine performance level to the remote server 414. Finally, at step1014, the remote server 414, after conducting the above discussedanalysis on the received data, transmits an ideal reactor performancelevel and instructions on how to achieve the ideal reactor performancelevel to the ECU 108. This in turn results in improved reactor 102's andengine 104's performance.

Referring now to FIG. 5, FIG. 5 is a block diagram illustrating anotherexemplary embodiment of system 100. System 500 comprises a number offunctional elements including a reactor 502, an engine 504, an enginecontrol module (“ECM”) 506, an electronic control unit (“ECU”) 508, aplurality of sensors 510 coupled to the reactor 502, a reactor controlboard (“RCB”) 512, a storage module 514 coupled to the ECU 508, adisplay module 516 coupled to the ECU 508, and a remote server 518 incommunication with the ECU 508. This embodiment is a combination ofembodiments represented in FIGS. 1-4.

In another exemplary embodiment of system 100, the ECU 108 can adjustthe reactor performance level or gas production rate in a way toselectively optimize engine performance indicators. Engine performanceindicators are calculated using the plurality of engine parameters,discussed above. Engine performance indicators are targets that thesystem 100 wants to achieve. For instance, engine performance indicatorsare, but not limited to, fuel efficiency, emissions, engine torque, andengine horsepower. Depending on which engine performance indicators areselected, the system 100 maximizes the selected engine performanceindicators according to the priority assigned to the selected engineperformance indicators.

Referring now to FIGS. 1 and 3, the user selects the engine performanceindicators that he/she desires to optimize and ranks them based on apriority that she/he has in mind through the display module 314. The ECU108 adjust the reactor performance level or gas production rate tooptimize each of the selected engine performance indicators ranked fromhighest to lowest. Consider the following example.

For instance, there are situations where emissions will out rank fueleconomy. Consider a case that the engine performance indicators areordered as: 1) emissions reduction and 2) fuel savings. In this example,the ECU 108 monitors emissions and adjusts the reactor performance levelor gas production rate to reduce emissions first. It continues to adjustthe reactor performance level or gas production rate to reduce emissionsup to the point of reaching a plateau or just before emissions begin torise again. This is the optimum point. At this point, the ECU 108focuses on reducing the fuel consumption, the engine performanceindicator ranked second in priority. As the fuel consumption is beingreduced, emissions are still being monitored to track any changes there.Once the fuel economy is optimized, a comparison between the twodifferent reactor performance levels or gas production ratescorresponding to optimizing emissions and fuel economy, respectively, ismade to find a best fit model that can optimize efficiency in all aspectof the engine performance. This found best fit model is the idealreactor performance level associated with simultaneously optimizingselected engine performance indicators. This method for improving theengine 104's and reactor 102's performance can be used with one ormultiple engine performance indicators.

Numerous specific details are set forth herein in order to provide athorough understanding of the exemplary embodiments described herein.However, it will be understood by those of ordinary skill in the artthat these embodiments may be practiced without these specific details.In other instances, well-known methods, procedures and components havenot been described in detail so as not to obscure the description of theembodiments. Furthermore, this description is not to be considered aslimiting the scope of these embodiments in any way, but rather as merelydescribing the implementation of these various embodiments.

The invention claimed is:
 1. A system for managing an on-demandelectrolytic reactor for supplying hydrogen and oxygen gas to aninternal combustion engine, the internal combustion engine being locatedin a vehicle, the system comprising: a plurality of sensors coupled tothe reactor, the plurality of sensors configured to measure a pluralityof reactor parameters; an electronic control unit coupled to theplurality of sensors and the engine, the electronic control unitconfigured to: monitor the plurality of reactor parameters and aplurality of engine parameters; determine a reactor performance levelbased on a parameter value associated with at least one of the pluralityof reactor parameters; determine an amount of hydrogen gas beinggenerated by the reactor, the amount of hydrogen gas being determined byprocessing one or more parameter values associated with one or morereactor parameters; determine an engine performance level based on aparameter value associated with at least one of the plurality of engineparameters; predict a change in the engine performance level at apredetermined future time to forecast a future engine demand level,wherein the prediction is based on one or more parameter valuesassociated with one or more engine parameters and terrain conditiondata; and determine an ideal reactor performance level based on thefuture engine demand level and the amount of hydrogen gas beingproduced; and a reactor control unit coupled to the reactor and theelectronic control unit, the reactor control unit configured to:subsequently regulate the reactor in response to the ideal reactorperformance level determined by the electronic control unit by modifyingat least one of electrical current supplied to the reactor, electricalvoltage supplied to the reactor, and temperature of the reactor.
 2. Thesystem of claim 1, wherein the electronic control unit is furtherconfigured to recalibrate the one or more of the engine parameters basedon one or more of the plurality of reactor parameters.
 3. The system ofclaim 1, wherein the electronic control unit is further configured todetect an occurrence of at least one of the plurality of reactorparameters existing outside a normal operating range, and the electroniccontrol unit is further configured to regulate the reactor in responseto the occurrence.
 4. The system of claim 1, wherein the plurality ofreactor parameters comprises at least one of: water tank level,electrolyte level, supplied electrical voltage, supplied electricalcurrent, water tank temperature, reactor temperature, reactor leakage,water pump, gas flow, relative humidity, conductivity of electrolyte,resistance of electrolyte, and concentration of electrolyte.
 5. Thesystem of claim 1, wherein the prediction is additionally based on oneor more parameter values associated with one or more engine parametersand location data associated with the vehicle comprising the internalcombustion engine.
 6. The system of claim 1, wherein the plurality ofengine parameters comprises at least one of: odometer, engine speed,fuel consumption, mass air pressure, mass air flow, mileage, distance,fuel rate, exhaust temperature, NO_(x) levels, CO₂ levels, O₂ levels,engine instantaneous fuel economy, engine average fuel economy, engineinlet air mass flow rate, engine demand percent torque, engine percentload at current speed, transmission actual gear ratio, transmissioncurrent gear, engine cylinder combustion status, engine cylinder knocklevel, and after treatment intake NO_(x) level preliminary FMI,drivetrain, vehicle speed, and GPS location.
 7. The system of claim 1,further comprising a memory coupled to the electronic control unit, thememory storing parameter values associated with the plurality of reactorparameters and the plurality of engine parameters, the memory furtherstoring the reactor performance level, and the engine performance level.8. The system of claim 1, wherein at least a performance indicator isdisplayed, the performance indicator being based on at least one of: atleast one of the plurality of reactor parameters, at least one of theplurality of engine parameters, the reactor performance level, and theengine performance level.
 9. The system of claim 1, wherein a firstplurality of data is transmitted to a remote server and a secondplurality of data is received from the remote server, the firstplurality of data comprising parameter values associated with theplurality of reactor parameters and the plurality of engine parameters,the reactor performance level, and the engine performance level, and thesecond plurality of data comprising the ideal reactor performance leveland instructions to the electronic control unit for achieving the idealreactor performance level, the second plurality of data generated basedon at least one of historical trends of the transmitted first pluralityof data and comparison to other first plurality of data transmitted fromother electronic control units in communication with the remote server.10. The system of claim 8, wherein the electronic control unitcommunicates with the remote server to find similar engine conditions todetermine the ideal reactor performance level.
 11. The system of claim1, wherein the ideal reactor performance level is determined based onpriorities assigned to one or more engine performance indicators,wherein the engine performance indicators can be selected from the groupconsisting of fuel efficiency, emissions, engine torque, and enginehorsepower.
 12. A method for managing an on-demand electrolytic reactorfor supplying hydrogen and oxygen gas to an internal combustion engine,the internal combustion engine being located in a vehicle, the methodcomprising: providing a plurality of sensors coupled to the reactor, theplurality of sensors configured to measure a plurality of reactorparameters; monitoring the plurality of reactor parameters; determininga reactor performance level based on a parameter value associated withat least one of the plurality of reactor parameters; determining anamount of hydrogen gas being generated by the reactor, the amount ofhydrogen gas being determined by processing one or more parameter valuesassociated with one or more reactor parameters; monitoring a pluralityof engine parameters; determining an engine performance level based on aparameter value associated with at least one of the plurality of engineparameters; predicting a change in the engine performance level at apredetermined future time to forecast a future engine demand level,wherein the prediction is based on one or more parameter valuesassociated with one or more engine parameters and terrain conditiondata; determining an ideal reactor performance level based on theforecast future engine demand level and the amount of hydrogen gas beingproduced; and subsequently regulating the reactor in response to thedetermined ideal performance level by an electronic control unit,connected to the plurality of sensors, by modifying at least one of:electrical current supplied to the reactor, electrical voltage suppliedto the reactor, the frequency, the amplitude, and temperature of thereactor.
 13. The method of claim 12, further comprising recalibratingone or more engine parameters based on one or more of the plurality ofreactor parameters.
 14. The method of claim 12, further comprisingdetecting an occurrence of at least one of the plurality of reactorparameters existing outside a normal operating range; and regulating thereactor in response to the occurrence.
 15. The method of claim 12,wherein the plurality of reactor parameters comprises at least one of:water tank level, electrolyte level, supplied electrical voltage,supplied electrical current, water tank temperature, reactortemperature, reactor leakage, water pump, gas flow, relative humidity,conductivity of electrolyte, resistivity of electrolyte, andconcentration of electrolyte.
 16. The method of claim 12, wherein theplurality of engine parameters comprises at least one of: vehicle speed,odometer, engine speed, fuel consumption, fuel rate, mass air pressure,mass air flow, mileage, distance, exhaust temperature, NO_(x) levels,CO₂ levels, O₂ levels, engine instantaneous fuel economy, engine averagefuel economy, engine inlet air mass flow rate, engine demand percenttorque, engine percent load at current speed, transmission actual gearratio, transmission current gear, engine cylinder combustion status,engine cylinder knock level, and after treatment intake NO_(x) levelpreliminary FMI, drivetrain, and GPS location.
 17. The method of claim12, further comprising storing parameter values associated with theplurality of reactor parameters and the plurality of engine parameters,the method further comprising storing the reactor performance level, andthe engine performance level.
 18. The method of claim 12, furthercomprising visually displaying a performance indicator based on at leastone of: at least one of the plurality of reactor parameters, at leastone of the plurality of engine parameters, the reactor performancelevel, and the engine performance level.
 19. The method of claim 12,further comprising transmitting a first plurality of data to a remoteserver and receiving a second plurality of data from the remote server,the first plurality of data comprising the plurality of reactorparameters, the plurality of engine parameters, the reactor performancelevel, and the engine performance level, and the second plurality ofdata comprising the ideal reactor performance level and instructions tothe electronic control unit for achieving the ideal reactor performancelevel, the second plurality of data generated based on at least one ofhistorical trends of the transmitted first plurality of data andcomparison to other first plurality of data transmitted from otherengines to the remote server.
 20. The method of claim 12, wherein theideal reactor performance level is determined based on prioritiesassigned to one or more engine performance indicators, wherein theengine performance indicators can be selected from the group consistingof fuel efficiency, emissions, engine torque, and engine horsepower.